Drywall Cornering Tool

ABSTRACT

The present invention provides an improved drywall cornering tool adapted for receipt of a cone liner said improved drywall cornering tool including a pole attachment, a pyramid shaped head centrally aligned about the pole attachment and extending from an apex to a bottom where the pyramid shaped head is configured for receiving of a disposable cone liner.

CROSS CLAIMS TO RELATED APPLICATION

The present invention claims the benefit of the presently pending,provisional application filed on May 25, 2018 U.S. App. 62/676,402entitled Drywall Cornering Tool.

FIELD OF THE INVENTION

The present invention is broadly directed to the field of drywallconstruction and more particularly to a drywall cornering tool thatprovides for an improved method and device for finishing a drywallcorner on three sides.

BACKGROUND OF THE INVENTION

Mudding or applying joint compound to sheetrock in a finished space haslong been considered an art form because of the difficulty in applyingthe joint compound in a uniform visually appealing manner.

Typically joining sheet of sheetrock together involves applying jointcompound and tape, in consecutive passes over several hours. Severalcoats of joint compound must be applied manually and then thinneduniformly allowing for time to dry between coats. After the jointcompound is dried, it is then sanded create a uniform surface. This isespecially true for the areas like inside corners where three drywallsheets meet together for example along a vertical, horizontal and third.It is difficult to apply joint compound along all three axes at the sametime. The problem with traditional corners is that only one side at atime can be tooled. If an attempt is made to tool both sides of a cornerat the same time, either the guide on the mud dispensing box willdisturb (and ruin) the mud on the other side of the corner, or the mudcoming out of the box will flow onto the other side. In either case, thecorner would be left in an unacceptable condition.

This often requires that tooling or boxing must be done on one side ofeach corner at a time. One side is tooled, then the joint compound mustbe allowed to dry, a process that requires coming back at least a daylater. Only after the joint compound on the first side is totally dry,can the second side be tooled. As a result, drywall workers musttypically pass through a construction site tooling the first sides ofeach inside corner. Then they must come back on a subsequent day to toolthe second side of the inside corners. This puts at least an extra dayinto the construction cycle. Thus, there is a need for an improvedmanner of mudding a corner which applies joint compound along all threeaxes uniformly and efficiently while saving time.

Prior attempt at addressing this problem include using a joint knife ortool which applies joint compound along a planar surface. However, theseare time consuming and difficult to use. The knife, having a sharpstraight edge, can damage or move the tape while spreading the jointcompound leading to a weak or visually displeasing corner. In addition,a mudding knife manually spreads joint compound along a sheetrock pairas spreads the applied compound thinly. However, it can only be usedalong one plane at a time. In addition to being inefficient, using themudding knife to spread joint compound along one plane may actuallyscrape or damage the surface of the adjacent sheetrock plane. Therefore,there exists a need to apply joint compound to along three dimensionsefficiently and without damaging the adjacent surface.

Another attempt to address the above-mentioned problem includes using acornering tool. The cornering tool is manually used to spread jointcompound along a pair of sheetrock surfaces joined together at an angle.The cornering tool also referred to as a butterfly has historically beenviewed as inefficient, unstable and difficult to work with, oftenresulting in application of a non-uniform bead or surface betweenadjacent sheets. In addition, the cornering tool may also damage or movethe tape joining the adjacent sheets while spreading joint compoundalong the two sheets. The cornering tool is also limited to workingalong two planes and is not configured for spreading joint compound orwork along all three axis simultaneously. Therefore, there exists a needfor an improved drywall cornering tool which can be used to joinsheetrock together along an inside corner in an efficient, effectivevisually appealing manner.

Accordingly, there is a need for an improved method and device forfinishing a three-sided drywall corner, like an inside corner which isquicker, easier and more efficient and at least in part, addresses theaforementioned shortcomings.

SUMMARY OF THE INVENTION

In one embodiment of the present invention, an improved drywallcornering tool is adapted for receipt of a disposable cone liner saidimproved drywall cornering tool comprising a pole attachment, a pyramidshaped head aligned about said pole attachment and extending from anapex to a bottom and said pyramid shaped head configured for receipt ofa disposable cone liner extending from said apex to said bottom.

The present invention relates to drywall corner tools that apply a coneliner to a mudded surface while the mud is still wet. The cone linerextends downward from an apex along three substantially planar sides,which once applied by the drywall cornering tool provides a flatfinished surface to the three sides which is prepared to receive paintor texture. This apex is fabricated from a partially plastic material,while the downward extensions are substantially fibrous, includingpaper. Each finished side can be mudded without any mud on the apex.This then allows for mudding of the remaining sides without anyinterference to the first side.

The cornering tool applies the cone liner in a way to resemble astandard drywall corner. At the apex is the finished surface that neverneeds mud. The surface of the apex can be finished in any way that willallow it to take paint or texture. It can be roughed slightly, or it canbe coated by a material to which paint or texture will adhere. The beadcan be made from any plastic, high impact plastic, metal, or any otherrigid material.

In the process, the worker applies the cone liner (which may be sizedaccordingly based on the desired corner dimensions) to the drywallcornering tool. Upon receipt of the cone liner, the user raises the tooland presses the head against the desired corner applying the liner intothe corner. The cone liner may be applied to the corner by any method(nailing, gluing, or mudding), mudding the first side. Immediately aftermud is applied to the first side, the worker can move to the second sideand mud it in an identical manner and then move to the third side andmud it in the same way. The corner is thus totally mudded in minuteswithout any drying wait period. The cone liner can be configured toprovide for a regular or bullnose style cornering beads, and interiortrim or flex-trim for interior corners and can be custom or standarddimensions.

Various objects and advantages of the present invention will becomeapparent from the following description taken in conjunction with theaccompanying drawings wherein, by way of illustration and example,certain embodiments of this invention are set forth. The drawingssubmitted herewith constitute a part of this specification, includeexemplary embodiments of the present invention, and illustrate variousobjects and features thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a bottom perspective view of an exemplary embodiment of thepresent invention attached.

FIG. 2 is a side perspective view of the exemplary embodimentillustrated in FIG. 1.

FIG. 3 is a top perspective of the exemplary embodiment illustrated inFIG. 1 with a head adapted for receipt of an exemplary cone liner.

DETAILED DESCRIPTION OF THE INVENTION

As required, detailed embodiments of the present invention are disclosedherein; however, it is to be understood that the disclosed embodimentsare merely exemplary of the invention, which may be embodied in variousforms. It will be readily understood that the components of the presentinvention, as generally described and illustrated in the figures herein,may be arranged and designed in a wide variety of differentconfigurations. Thus the following specific structural and functionaldetails disclosed herein (including the drawings) are not to beinterpreted as limiting, but merely representative of the selectedembodiments of the invention and as a basis for the claims and as arepresentative basis for teaching one skilled in the art to variouslyemploy the present invention in virtually any appropriately detailedstructure.

The features, structures or characteristics of the invention describedthroughout this specification may be combined in any suitable manner inone or more embodiments. For example, the usage of the phrases “exampleembodiments,” “some embodiments,” or other similar language, throughoutthis specification refers to the fact that a particular feature,structure, or characteristic described in connection with the embodimentmay be included in at least one embodiment of the present invention.Thus, appearances of the phrases, “example embodiments,” “in someembodiments,” “in other embodiments,” or other similar language,throughout this specification do not necessarily all refer to the samegroup of embodiments and the described features, structure orcharacteristics may be combined in any suitable manner in one or moreembodiments.

Referring to the drawings in more detail, and specifically FIG. 1, thereference numeral 10 generally refers to a new and improved drywallcornering tool with a mountable attachment 6, for example, as a poleattachment or adapted for use with a hand tool or extension tool (notshown). Generally, the pole attachment 6 presents a central axis aboutwhich a pyramid shaped head 20 is aligned. The illustrated embodiment ofthe mountable attachment 6, in FIG. 1, includes a threaded memberadapted for threadable receipt by another device like a pole, but couldbe alternatively configured for receipt by another tool or extensiondevice (not shown) which includes a quick release fitting (not shown) orother releasable fastening mechanism generally known.

In addition, the mountable attachment 6 includes a circular spacer witha frictional outer surface which separates the threaded receiver (notshown) from a biasing member 14 and allows for a better rotationalgripping surface while attaching the pyramid shaped head 20 to theextension device (not shown).

The pyramid shaped head 20 extends from an apex 25 to a bottom 19 and isadapted for receipt of a cone liner 18 for finishing or boxing drywallcorners like inside corners (not shown). In general, the drywallcornering tool 10 with pyramid shaped head 20 and cone liner 18 is usedto simplify and expedite the drywall process. Use of the pyramid shapedhead 20 for the finishing or drywall process allows for concurrentpressure against multiple sheetrock sheets during drywalling.

The depicted embodiment of the pyramid shaped head 20 of FIGS. 1-2includes a first triangular face 24, second triangular face 26 and thirdtriangular face 28 joined together along a plurality of edges. Each ofthe first, second and third faces 24, 26, 28 include a first, second andthird notch 17 a, 17 b, 17 c at each vertex of each first, second andthird triangular face 24, 26, 28.

As generally depicted in FIG. 2, a first edge 23 a extends between thefirst face 24 and the second face 26, a second edge 23 b extends betweenthe second face 26 and the third face 28 and a third edge 23 c extendsbetween the third face 28 and the first face 24. Each of the first,second and third edges 23 a, 23 b, 23 c extend from the apex 25, wherethe first, second and third triangular faces 24, 26, 28 present acentral vertex 27, downward for presentation of the bottom 19.

By applying concurrent pressure against all three triangular faces 24,26, 28 a smoother, cleaner corner finish may be obtained. In addition,by applying concurrent pressure against the first, second and thirdtriangular face 24, 26, 28, the corner finish may be obtained morequickly and without damage to the adjacent sheetrock surfaces which maybe caused by consecutive finish of adjacent sheetrock surfaces. Use ofthe drywall cornering tool 10 allows for a quicker, more consistentcornering process than traditional corning methods and tools providewhile boxing the drywall corner along adjacent sheets of drywall.

Generally, the head 20 provides a unique edge surface for applying thecone liner 18. The head 20 may be fabricated from plastic, metal, rubberor such materials as are well known or a combination of any of thosematerials. The cone liner 18 may be reinforced or fabricated for usewith or without joint compound at the tip of the liner 18. Depending onthe reinforcement provided, application of joint compound may beunnecessary and the user may be able to mud one side of the linerwithout interfering with the other sides.

The embodiment illustrated in FIG. 3 includes the cone liner 18 or papercone which is adapted for receipt by the pyramid shaped head 20.Generally, the cone liner 18 has a complementary opening for receipt ofthe pyramid shaped head 20. In one embodiment, the cone liner 18includes a plurality of liner faces including a first liner face 18 a, asecond liner face 18 b, and a third liner face 18 c which extendsdownward from a center 18 d. In one embodiment, the center 18 d is atleast partially rigid to provide a straighter edge for forming the shapeof the inside corner formed at the junction of three or more sheetrocksurfaces (not shown). Generally, the cone liner 18 may be fabricatedfrom plastic, paper or a combination of plastic and paper.

Radiating outwardly from the center 18 d, the fibrous materialassociated with the cone liner 18 absorbs or is coated by the jointcompound (not shown). In addition, the fiber portions provide for lesstouch up or check out in the angle. The system including the improveddrywall corner tool 10 with cone liner 18, will speed up theinstallation process, provide for easier installation and clean-up ofdrywall material, providing for better more visually appealing corners.

In one embodiment of the present invention, at least one plurality ofspacers 21 extend from the head 20 depicted in FIG. 1. Each spacer 21extends along each face 24, 26, 28 for separation of the cone liner 18from the head 20. Generally, the spacers 21 are mechanically fastenedwith spacer fasteners 29 to each of the triangular faces 24, 26, 28. Byproviding a raised surface extended from the substantially planarsurface of the triangular face 24, 26, 28, the spacers 21 help provideuniform pressure against the cone liner during application and assist inspacing the received cone liner 18 from the head 20 and in selectivelyapplying the cone liner 18 into the adjacent sheetrock surfaces formingthe inside corner.

A crown 12, is illustrated in FIG. 1, extended from the pole attachment6 configured for telescopic movement with a biasing member 14 incommunication with the pole attachment 6. As the biasing member 14 iscompressed, the crown 12 extends vertically along the central axis. Thecrown 12 is operably connected to the first, second and third triangularfaces 24, 26, 28 with a brace 22. The depicted embodiment of the crown12 is circular with arcuate brace connectors which are configured forreceipt of a frustoconical spacer 12 a which as depicted in FIG. 2extends between the biasing member 4 and the crown 12 for telescopicmovement of the crown 12. As the crown 12 moves telescopically the brace22 provides outward support for each of the triangular faces 24, 26, 28.

As illustrated in FIG. 1, one embodiment of the head 20 is attached tothe pole attachment 6 using a reactionary supporting structure. Inanother embodiment, the head 20 moves during telescopic operation of thecrown 12.

The embodiment of the reactionary support structure illustrated in FIG.1 includes at least one brace 22 extending from the crown 12 to at leastone rib 16. As pressure is exerted upon the first, second and thirdtriangular faces 24, 26, 28, the force is distributed from the rib 16 tothe corresponding brace 22 along the other reactionary support members.During static operation, the reactionary support structure assists insupporting and connecting the head 20 along the central axis extendingalong the pole attachment 6. The rib 16 is illustrated in FIG. 1 asbeing secured along the interior side of the first, second and thirdtriangular faces 24, 26, 28 with the rib 16 mechanically secured to eachof the triangular faces 24, 26, 28 with a mechanical fastener 16 d. Theembodiment of the mechanical fastener 16 d includes a cylindrical endsecured through the triangular face, but may also include a number ofother fasteners including mechanical, or chemical such as a rivet, bolt,screw, nail, glue, or welded. Alternatively, the ribs 16 may be formedas part of the manufacturing process such as plastic molding.

During extended operation, such as when applying the cone liner 18within an inside corner (not shown), each triangular face 24, 26, 28extends radially by the telescopic operation of the crown 12 to applyuniform pressure against the cone liner 18 and assist in impregnatingthe cone liner 18 into the inner corner surface (not shown). Thereactionary support structure includes the braces 22 extending from thecrown 12 to each face 24, 26, 28. The optional biasing member or topspring 14 assists in the upward extension of the crown 12 for outwardextension of the brace 22, for example, during telescopic movement.

The reactionary support structure allows for redistribution of pressurefrom one of the triangular faces 24, 26, 28 along all faces on the head20 reducing the pressure exerted along any single sheetrock surface (notshown) individually and distributing it along all sheetrock surfacescollectively. Reactionary support structures, other than the depictedrib 16 and brace 22 combination may be utilized for distribution of theforce from at least one of the triangular faces 24, 26, 28 to the othertriangular faces during static or extended operation of the head 20.

The illustrated embodiment of the rib 16 in FIG. 1 is an elongatedrectangular structure with a pair of side members 16 a spanning a bracereceiver 16 b adapted for pivotal receipt of the brace 22 about acentrally extending support pin 16 c. Each rib 16 extends verticallyalong the interior surface of each first, second and third triangularface 24, 26, 28 and interconnects the brace 22 to each triangular face24, 26, 28. Each rib 16 is attached to one end of a brace 22, the otherend of the brace 22 being attached to the adjustable crown 12. Duringoperation, each brace 22 extends outwardly as the crown 12 istelescoped.

FIG. 2 illustrates an embodiment of the head 20 with each face 24, 26,28 extending from the apex 25 downwardly. In the depicted embodiment ofthe triangular shaped faces 24, 26, 28 are substantially planar and aretriangular shaped. The spacing of each edge 23 a, 23 b, 23 c from eachpair of adjoining triangular faces, 24, 26, 28 presents a bullnose edgealong each edge surface 23 a, 23 b, 23 c.

FIG. 3 includes the head 20 and the cone liner 18, the cone liner 18being shaped for overlying the head 20 during operation.

The cone liner 18 may be fabricated to be finished directly or beprepared to receive paint or texture. This preparation can be a slightlyroughed surface, or a coating of any suitable material that paint ortexture will adhere to. If the structure is a laminate containing anouter paper layer, the paper can be of a type that can directly receivepaint or texture, or it can be prepared to receive paint or texture witha suitable coating. The entire surface of the cone liner 18 couldoptionally be bonded with paper that can directly receive paint ortexture.

It is to be understood that while certain forms of the present inventionhave been illustrated and described herein, it is not to be limited tothe specific forms or arrangement of the parts described and shown.

What is claimed and desired to be secured by Letters Patent:
 1. Animproved drywall cornering tool adapted for receipt of a cone liner saidimproved drywall cornering tool comprising: a pole attachment; a pyramidshaped head aligned about said pole attachment and extending from anapex to a bottom; and said pyramid shaped head configured for receipt ofa disposable cone liner extending from said apex to said bottom.
 2. Theimproved drywall cornering tool of claim 1 wherein said pyramid shapedhead further comprising: a first triangular face, a second triangularface, a third triangular face spaced between said second triangular faceand said first triangular face; said first triangular face and secondtriangular face spanned by a first edge; said second triangular face andsaid third triangular face spanned by a second edge; and said thirdtriangular face and said first triangular face spanned by a third edgewherein said first edge, said second edge and said third edge extendsubstantially from said apex to said bottom.
 3. The improved drywallcornering tool of claim 2 wherein said first triangular face, saidsecond triangular face and said third triangular face are substantiallyplanar.
 4. The improved drywall cornering tool of claim 2 wherein saidfirst triangular face, said second triangular face and said thirdtriangular face present a central vertex.
 5. The improved drywallcornering tool of claim 2 wherein at least one of said first triangularface, said second triangular face and said third triangular faceincludes a notch.
 6. The improved drywall cornering tool of claim 1wherein said pyramid shaped head further comprising at least one spacerextending outwardly from said head.
 7. The improved drywall corneringtool of claim 1 wherein said pyramid shaped head further comprises areactionary support structure extending between said pole attachment andsaid pyramid shaped head.
 8. The improved drywall cornering tool ofclaim 7 wherein said reactionary support structure further comprises: acrown a rib; and a brace extending between said crown and said rib. 9.The improved drywall cornering tool of claim 8 wherein said crown iscentrally aligned with a center axis, said brace is mounted to saidpyramid shaped head, said brace extending therebetween.